Prefabricated buildings, components and methods of erection of prefabricated buildings

ABSTRACT

This invention is a new concept in prefabricated buildings, components and methods of making the components and methods of erecting the buildings. A typical wall of the new building consists of a plurality of alternately positioned wall panels and support columns, where each support column is situated between two adjacent facing side edges of two wall panels. Coupling elements connect the support column to the two panels, and a single activation element on the support column causes these coupling elements to pull the wall panels into correct elevation and secure engagement with the support column and also secures the support column to an anchor pin in the foundation directly below the support column. This support column consists of an outer tube and a shaft slidable within the tube. First coupling elements extending from each side edge of the support column, and mating second coupling element are situated in the side edges of each panel for cooperation with the first coupling elements. Drawing the shaft upward causes mutual engagement of the first and second coupling elements and causes secure engagement of the support column with the anchor pin.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. 119, 120 based uponapplicant's Provisional Application, Ser. No. 60/857,732, filed Nov. 7,2006.

I. BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is in the field of prefabricated buildings and methods oferection of prefabricated buildings.

2. Background

There is a worldwide need for buildings of all types, including homes,hospitals, school and factories, this need being particularly acute inareas of natural disasters such as occurred with the Tsunami andHurricane Katrina and in war-torn areas. The need is also great in manyunder-developed areas and countries and even in developed countrieswhere cost, speed and ease of construction have become great concerns.Thus, a first set of basic objectives is for prefabricated homes thathave low cost, safe and secure construction, good insulation from heatand cold and durability. Obviously, an attractive appearance would bequite desirable since many prior art prefabricated buildings havenondescript or poor appearance. Fireproofing is a still furtherobjective, but difficult and expensive because conventional materialsare primarily wood and wood products.

Vast amounts of wood materials are used and thus consumed in worldwidehome and building construction for framing, inner and outer walls,floors and roofs. Thus, a worldwide wood consumption cycle is well alongwith no end in sight, as forests are being destroyed and wood fromdemolished and replaced homes is often burned or otherwise disposed ofwithout useful recycling. Another problem in prefabricated buildingconstruction is the time to manufacture components, to transport anderect the components, and a requirement for skilled persons withprofessional equipment and power tools to achieve assembly and erectionof the buildings. Finally, the economics of high volume usuallyprecludes much variety or esthetic considerations.

II. OBJECTS AND SUMMARY OF THE NEW INVENTION

This present invention includes a new prefabricated building concept,components, sub-assemblies, fully erected buildings and a method ofassembly or erection of such buildings. A principal object of thisinvention is to provide buildings that can be erected very quickly andeasily and by persons who may not be professionals in this field and whomay have little or nor power equipment, and/or who may be erecting suchbuildings in remote and primitive regions.

A further object of this invention is to provide buildings, and housingtype buildings in particular, that are extremely inexpensive as regardscost of components and labor.

Another object of this invention is to provide prefabricated housingthat can be erected by persons who do not need to be trained andexperienced carpenters, bricklayers, plumbers, electricians, painters,etc.

A still further object of this invention is to provide prefabricatedhousing which is strong, safe, well insulated from heat and cold and isfireproof.

An additional object of this invention is to provide prefabricatedhouses that do not require wood as a basic construction component, whichhelps conserve the world's forests from destruction.

A related object of this invention is to provide housing having suchgood insulation characteristics at a reasonably low cost, that therewill be a greatly reduced need for heating fuel, be it from wood, woodproducts, coal, oil, gas, or even electrical, and wind power. Suchreduced fuel needs conserve natural resources, reduce environmentalpollution from combustion and reduce operational costs of living in suchbuildings.

A still further object of this invention is for the components of suchnew buildings, particularly the modular wall, roof and floor panels, tobe light weight and thus easy and inexpensive to transport and to handleduring erection of the buildings.

An additional object of this invention is to use components,particularly wall, roof and floor panels, which can be manufactured infactories that can be easily set up near the locations where thebuilding will be erected.

A further object of this invention is for the coupling elements thatjoin wall panels and other components to be simple to understand andeasy to use.

An additional object is for these buildings to be adapted for assemblyin rural or even remote and undeveloped areas, including deserts andjungles, where conventional roads, machinery, equipment and skilledartisans are few or non-existent.

These and other objects of the invention will be further understood andappreciated by those skilled in the art by reference to the followingwritten specification, claims and appended drawings.

III. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially cut-away top perspective view of a prefabricatedbuilding of this invention,

FIG. 2 is an exploded view of a typical wall panel as used in thebuilding of FIG. 1,

FIG. 3 is a perspective view of the wall panel of FIG. 2 in its finalassembled state,

FIG. 4 is a fragmentary sectional view taken along line 4-4 in FIG. 3showing the pocket and pin arrangement in the edge of the panel of FIGS.2 and 3,

FIG. 4A is a sectional elevation view taken along line 4A-4A in FIG. 4,

FIG. 5 is a fragmentary and exploded perspective view of two wall panelsas seen in FIGS. 2 and 3 positioned to be coupled to a Drawlock columnbetween their adjacent edges,

FIG. 6 is a fragmentary perspective view of the two panels of FIG. 5after they have been drawn to and coupled with the column,

FIG. 7 is a fragmentary exploded perspective view of a column of FIG. 5to which wall panels are attached,

FIG. 7A is a fragmentary top front perspective view of the column ofFIG. 7 connected to a foundation,

FIG. 7B is a fragmentary top perspective view of the column of FIG. 7 towhich roof truss beams are coupled,

FIGS. 8-10 show the column in progressive stages of its coupling withwall panels, where FIG. 8 is a fragmentary elevation view showingschematically how draw pins in edge pockets of opposite wall panelsapproach coupling wings of the column,

FIG. 9 is a fragmentary perspective view of the column of FIG. 8 showinghow the draw pins of the opposite wall panels have been drawn inward tothe column and upward to their final location,

FIG. 10 is a fragmentary elevational sectional view taken along line10-10 in FIG. 9 further showing the side panels fully coupled to thecolumn and showing the position of the draw bar within the column,

FIG. 10A is a side elevation view in section of the column of FIG. 6showing schematically a force diagram of forces applied to the draw bar,the column, the foundation and the draw pin,

FIG. 11 is a fragmentary sectional view taken along line 11-11 in FIGS.1 and 10 showing the draw pins in side panel pockets fully coupled withthe wing tabs of the draw bar and of the column,

FIG. 12 is a fragmentary elevational sectional view taken along line12-12 in FIG. 10, showing the coupling of the bottom end of the drawshaft with the anchor,

FIG. 13 is a fragmentary elevational view in section, partially similarto FIG. 10, showing the top end of the draw shaft within the column whenopposite wall panels are drawn-in and coupled to the columns,

FIG. 14 is a fragmentary sectional elevational view taken along line14-14 in FIG. 13, showing the column and its coupling to roof trussbeams,

FIG. 14A is a top sectional view along line 14A-17A in FIG. 14,

FIG. 14B is a top perspective view of the roof truss coupling to a wallcolumn,

FIG. 15 is a fragmentary sectional plan view along line 15-15 in FIG. 1,showing the coupling of two wall panels to a column forming the cornerconstruction of the building,

FIG. 16 is a fragmentary sectional view taken along line 16-16 in FIG.1, showing a set of adjacent roof panels coupled to a column betweenthem,

FIG. 17 is a fragmentary sectional view taken along line 17-17 in FIG.1, showing the junction of the top ends of adjacent roof panels at thepeak of the roof,

FIG. 18 is a fragmentary sectional elevation view, corresponding to FIG.12, but showing a second embodiment of connection of the bottom of thecolumn and draw shaft to the foundation;

FIGS. 19-21 show a sequence of stages of assembly or erection of atypical wall of wall panels and columns, and

FIG. 22 is an exploded perspective view of a bookend mold module formanufacture of a wall panel.

The features of the invention will become apparent from the followingdescription of the exemplary embodiments taken in conjunction with theaccompanying drawings.

IV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For convenience and clarity in describing the preferred embodiments,similar elements or components appearing in different figures and indifferent embodiments will have the same reference numbers.

FIGS. 1 to 22 illustrate my new prefabricated building invention whichincludes: (a) an assembled prefabricated building, (b) the subassemblyof a single wall or wall section formed of key structural components ofwall panels and support columns, (c) a method of assembly or erection ofsuch a building, (d) a new wall panels alone, and (e) the method ofmaking the new wall panel.

A. General Description of the Prefabricated Building

A typical building 10 constructed according to this invention comprisesside and end walls 11 formed of alternately spaced wall panels 12 andsupport columns 14. Such walls are secured to a floor 22 or otherfoundation and support a roof 15 comprising a roof truss and roof panel18. More specifically, each side wall 11 is formed of alternatelypositioned upright wall panels 12 and upright support columns 14, whereeach column 14 is situated between and releasably coupled to facing sideedges 12A of two adjacent wall panels 12. A typical wall panel has widthof four feet and height of eight, ten or more feet in height. Obviously,a complete wall 11 comprising many wall panels 12 may vary in length andheight, and may include doors and windows as desired. Also, as discussedlater, wall panels 12, as modular units of wall 11, may have customizedsound and heat insulation properties, customized esthetic interior andexterior surfaces and built-in HVAC, plumbing and electrical components.Roof 15 is constructed in a manner generally similar to that of thewalls, with roof panels 18 releasably coupled to roof beams 20 situatedbetween facing side edges of adjacent roof panels. Optionally, otherroof structure is possible, but such would not necessarily employ andtake advantage of the present invention. The building also has floor 22and anchor 23 components, and may utilize floor panels, generallysimilar to wall panels but having properties appropriate for a floor.The support columns structurally integrate the walls, roof and floor aswill be described in later sections.

B. Wall Construction of Wall Panels and Support Columns

As noted above and as seen in FIGS. 1 and 5-11, walls 11 of the newprefabricated building are constructed of alternately spaced wall panels12 and support columns 14. For convenience, this description and theclaims will refer when appropriate to a coupling means 1 which comprisescoupling elements 2 and 3 for connecting wall panels 12 to a supportcolumn 14, anchor connection means 4 for securing a support column 14 tothe anchor means 23, and actuation means 5 for actuating said couplingmeans 1.

(1) Support Column

A typical support column 14 as seen in FIGS. 5-11 comprises an outertube 14A and a shaft or draw bar 25 slidable in tube 14A. Said outertube 14A has top part 14T, bottom part 14B and opposite side walls 14E.Tube 14A also has front or inside wall 14C and rear or outside wall 14Dthat correspond respectively to interior and exterior surfaces of walls12 of building 10.

The above mentioned coupling means 1 comprises first coupling elements 2on each side edge of each support column 14 and second coupling elements3 on each wall panel 12. As further described, each support column 14has on each side edge 14E five axially spaced coupling elements 3, eachcomprising a set of wings or jaws 29, 30. The five coupling elements 2(designated 2A-2E) on each side edge of column 14A are adapted tocooperate with five coupling elements 3 (designated 3A-3E) on the sideedge 12A of each wall panel 12. As illustrated, each coupling element 2comprises a set of wings, where wing 29 is fixed to side edge 14E ofouter tube 14 and wing 30 is carried by shaft 25 and movable to approachwing 29 when shaft 25 is drawn upward relative to outer tube 14A. Theactual number, size and form of coupling elements may vary from thepreferred constructions illustrated herein.

For cooperation with these five first coupling elements 2A-2E on eachside edge 14A of each support column 14 are five second couplingelements (3A-3E), each second coupling element comprises a recess 26 anda pin 43 in the side edge of a typical wall panel.

Each of coupling elements 2A-2E on support column 14 engages and locksonto a pin 43 of a corresponding coupling element 3A-3E of a panel whenthe panel is positioned for engagement and connection to the supportcolumn.

(2) Wall Panel

As seen in FIG. 2 particularly and in FIG. 2A, each wall panel 12 hasside edges 12A, and in each side edge 12A is a series of couplingelements 3A-3E, each consisting of a pocket or recess 26 and a pin 43fixed in the pocket. Each recess 26 and pin 43 fixed therein functionsas a coupling element 3 of coupling means 1 for connecting a wall panelto a support column 14. These recesses are axially spaced apart tocorrespond to and receive said axially spaced apart first couplingelements 2A-2E, each consisting of a set of wings 29, 30. The centralcore of panel 12 is urethane foam 38.

For each set of wings the movable wing 30 includes a hook-like groove30A. For coupling of a wall panel 12 to the support column 14, each setof wings extends laterally from the support column 14 into a recess 26in the side edge of wall panel 12 and engages and releasably coupleswith pin 43 in the panel. Thus, the panel is maneuvered into positionuntil each of the five recesses on one side edge receives therein oneset of wings, with pins 43 moving between each said two wings of eachset and into said locking groove 34.

As seen in FIGS. 7, 7A and 7B, in a typical set of wings the fixed upperwing 29 (a) has a tapered top edge 29A for easily entering acorresponding recess 26 in a panel side edge 14A, and (b) has agenerally flat or horizontal bottom edge 29B that has with a slightupward taper 29C at the outer end 29D. As seen in FIGS. 11 fixed or topwing 29 is displaced laterally behind movable wing 30 and toward theexterior side of column 14. The movable wing 30 of each set of wings issituated below top wing 29 and is axially movable within an axial slot31 in the side wall 14A of column 14.

Below each fixed wing 29 is movable wing 30 attached to and moved bydraw bar 25. At the top edge of wing 30 is a groove 30A creating ahook-like recess to receive and capture a pin 43 of coupling element 3of wall panel 12.

As noted above, each column 14 comprises an inner shaft or draw bar 25slidable within said outer tube 14A. As seen in FIG. 8 and also in FIGS.7, 7A and 7B, draw bar 25 has its own axial slots 32 to receive hookelements 33 of each lower wing 30. When assembling wings 30 onto drawbar 25, each wing 30 is moved laterally until its two hook elements 33enter and pass through slot 31 on the side edge of outer tube 14A ofsupport column 14, and thence each element 33 enters a slot 32 of drawbar 25 and drops down into full engagement. Later, upward movement ofdraw bar 25 will drive all hook elements 33 upward so that the edge ofgroove 30A in the top edge of hook element 33 will approach the bottomedge 29B of fixed wing 29 and capture pin 43 there between.

To achieve this arrangement of draw bar, wings and outer tubecomponents, movable wings 30 are attached after draw bar 25 is situatedwithin the bore of outer tube 14A and slot 32 is aligned with slot 31 ofouter tube 14. As seen, draw bar 25 has five axially spaced (movable)wings 30 on each side, which operate with five fixed wings 29 on eachside of outer tube 24, thus producing five sets of wings on each side ofcolumn 14. Each set of wings is one of the coupling elements 2A-2E.Axial movement upward of draw bar 25 within outer tube 14A will moveeach top and bottom end beam 39 and wing 30 upward toward correspondingfixed wing 29 of outer tube 14A.

Before describing how a panel 12 is coupled to column 14, first note thepanel structure as seen in FIGS. 2, 3, 4 and 5. Panel 12 consistsprimarily of inner frame 40 having side beams 41 with pockets 42 spacedalong the length of each side beam 41. Each pocket 42 is formed by agenerally triangular cup with pin 43 extending transversely across andfixed in each cup. In a manufacturing process to be described later,sheets or skins 44A, 44B are attached to frame 41 and become the insideand outside surfaces of wall panel 12.

Now, note that FIG. 5 shows two panels 12 being moved, as indicated byarrows 45, toward both opposite sides of a support column 14. Couplingelements 3A-3E, each comprising a pocket 26 and pin 43 are generallyaligned with coupling elements 2A-2E, each comprising a set of upper andlower wings 29, 30. FIG. 6 illustrates a section of wall 11 where twowall panels 12 have converged laterally against a column 14. FIG. 8indicates schematically how two wall panels (not shown) of FIG. 5approach opposite side edges of a column 14 and become coupled thereto.In FIG. 8 the wall panels are not shown, but representing each wallpanel is a circle 43A representing pin 43 as the wall panel is movedtoward column 14. If a wall panel's elevation is not properly alignedwith space 46 between upper and lower wings 29, 30, then taper edge 29Cof upper wing 29 will guide pin 43A into space 46 and then downward intogroove 30A.

FIGS. 8, 9, and 10 illustrate schematically two wall panels 12 movingand moved into engagement with both sides 14A of a single support column14. The two wall panels are not shown; however, pins 43A or 43Brepresents one of the coupling elements 2A-3G in a typical wall panel.Once wall panel 12 and its pin 43 (this pin representing the fivecoupling elements 3A-3E) moves sufficiently inward toward column 14, pin43 will reach the position indicated by 43B. At this time, upwardmovement of draw bar 25 has driven lower wing 30 upward, and taperededge 30B of wing 30 has driven or cam pin 43 (43B) further inward towardcolumn 14. Full upward movement of draw bar 25 drives pin 43 upwardagainst bottom edge 29B of fixed upper wing 29, which thus positionspanel 1 2 at the correct elevation relative to column 14. This guidanceand capture of pin 43 by wings 29, 30 positions and secures wall panels12 to support columns 14, creating walls of desired length. Because theproper alignment of each panel 12 is predetermined, the coupling means 1cannot overdraw or damage pin 43 or the panel in which it is fixed.

Activation of draw bar 25 within outer tube 14A of each column 25achieves a plurality of functions: (a) engaging and pulling the panelsto be closely adjacent the column, (b) moving the panels to the correctelevation and orientation relative to the column and (c) securing thepanels to the column. Said activation also releasably secures the columnand attached panels to the anchor, floor or other foundation 22.

As seen in FIGS. 5, 6 and 1, each column 14 has a bottom end 14B thatbecomes secured to the floor 22, anchor or other foundation componentand a top end 14T that becomes coupled to and supports roof 15. Eachcolumn 14 serves a plurality of different functions with simplicity,efficiency and security, as described below.

C. Operation of Draw Bar for Securing Wall Panels and Urging the SupportColumn Downward Against Foundation

FIGS. 9, 10, 10A and 12 illustrate a first embodiment 4A of the anchorcoupling 4, and FIG. 18 illustrates a second embodiment 4B of suchcoupling. As seen in these figures coupling 4A consists of rod 51 havinghook 52 at the bottom that engages horizontal anchor pin 53 that issecurely embedded or otherwise fixed in the floor 22 or in a jack stand100 (FIG. 9) secured in the ground. In the course of erecting a building10, draw bar 25 is coupled via rod 51 and hook 53 to anchor pin 53,which will anchor to the ground the connected components (draw bar 25,support column 14 and attached wall panels 12), as further explainedbelow.

As seen in FIGS. 9, 10 and 12, draw bar 25 has at its lower end, belowwings 30, variable length coupling 4A which consists of rod 51 whoselower end is pivotably coupled to anchor pin 53 and whose threaded topend is fixed via locking nuts 57 to blade 56. In FIG. 18 there is avariation in the form of an upward extending rod 55 whose top end issimilarly fixed to blade 56, but whose bottom end is fixed in the flooror foundation 22 with no pivoting capability. In both of theseembodiments blade 56 is secured to rod 51 or 55 respectively. Withlocking nuts 57 the elevation of blade 56 can be adjusted so that slot58 in blade 56 will have its top and bottom ends located atpredetermined elevations relative to anchor pin 53 or to the topreference surface 100A of the anchor pad or jack stand, whichever isestablished as the basic reference elevation.

As seen in FIG. 12, at the top end of slot 58 is pin 59 fixed to thelower end of draw bar 25. Further, as seen, draw bar 25 is in itsuppermost or second position, since pin 59 is barred from further upwardmovement by the top end of slot 58. In this upper position draw bar 25has pulled adjacent wall panels 1 2 closely and securely against thesupport column 14.

More specifically, when upright support column 14 is positioned directlyabove rod 51, and draw bar 25 (slidable within column 14) has its lowerend coupled to rod 51, draw bar 25 is then slidable within supportcolumn 14 within the limit of length L of slot 58.

This movement of draw bar 25 is coordinated with movable wings 30secured thereto, so that upward movement of draw bar 25 to its limit perslot 58, will bring each wing 30 to the predetermined correct elevationbelow wing 29 to pull wall panels 12 inwardly to the correct tightnessagainst column 14 and to the correct elevation relative to foundation orfloor 22.

D. Actuation Means “5” To Actuate Coupling Means “1”

As described briefly earlier, actuation means 5 actuates coupling means1 which pulls draw bar 25 upward and draws panels 12 inward againstsupport column 14. The actuation means 5 includes (a) main nut 74 onthreaded rod 66 extending from the top of draw bar 25, and (b) block 68fixed to a top portion of 14T of support column 14. As seen in FIGS. 13,14 and 14A, draw bar 25 is drawn upward relative to outer tube 14A byrotating main nut 74. As will be further described, the engagement ofthe bottom of draw bar 25 via coupling 4A to the anchor means 23,simultaneously secures outer tube 14A of column 14 to the floor 22 andsecures two wall panels 12 at the correct elevation and tightness tocolumn 14, while barring over tightening forces that might be applied topins 43 in the wall panels.

Coupling 4A has a height adjustment available via the set of lockingnuts 57, whereby variations in the elevation of the floor or foundation22 and length of rod 51 or 55 can be easily accommodated, so that alldraw bars 25 in the various support columns 14 and all wall panels 12will be at the same elevation.

E. Anchor Connection with Support Column

As seen in FIG. 13, the top end of tube 14A of column 14 includes fixedblock 68. The top end of draw bar 25 includes fixed block 65. Threadedrod 66 coupled to block 65 extends through bore 67 in block 68, androtation of main nut 74 on rod 66 pulls draw bar 25 upward relative toouter tube 14A. As seen in FIGS. 13 and 14, outer tube 14A of column 14in this embodiment is a rectangular tube having side walls 14E, front orinner wall 14C and rear or outer wall 14D. Block 68 fixed to outer tube14A of support column 14 is supported by resting on cut-out edges, 14X,14Y of front and rear walls 14C, 14D where it sits between side walls14E. Consequently, any downward pressure on edges 14X, 14Y, urges thesupport column 14 downward against the foundation 22.

Tightening of main nut 74 in a single step “locks down” column 14against the floor or foundation 22 and simultaneously pulls upward ondraw bar 25 and draws inward panels 12. More specifically, lock down nut74 when rotated by a wrench, bears downward on block 68 which bearsdownward on edges 14X, 14Y of outer tube 24 of column 14 which has itsbottom end 14B driven downward against the foundation 22.

The reason downward force on column 14 is achieved is that rotation ofnut 74 causes pulling upward on rod 66. As described earlier, rod 66 isfixed to the top end of draw rod 25 whose bottom end is coupled to thefixed floor or anchor. Also, as described earlier, pulling upwardinitially causes draw bar 25 to move upward, as wall panels 12 are drawninward to and against column 14. Continued upward pulling on draw bar25: (a) cannot further lift the draw bar because such is barred andlimited by slot 58 in anchor connection 5, and (b) can only applyfurther downward force on outer tube 14A of column 14 against thefoundation. Lock nut 74 is then torqued to the proper final force forthis assembly.

F. Anchor and Foundation

As seen in FIGS. 10, 10A, 12, and as described in Sections C and Dabove, the lower part of draw bar 25 engages a foundation or floor 22 oranchor 23 in the ground by anchor connection 4 comprising rod 51extending downward to anchor pin 53. As seen, rod 51 has a bottom hookend 52 that engages fixed pin 53 and a threaded top end. Also shown isanchor plate 54 whose neck is situated inside the bottom end of outertube 14A to stabilize it from horizontal slippage. As seen in FIG. 10A,tightening lock-down nut 74 atop block 65 fixed to outer tube 14A ofcolumn 14, pulls draw bar 25 upward, thus, affecting an upward force F1in rod 66, seen as force F1′in draw bar 25, and seen as force F1″ inanchor rod 51 and thus also on anchor pin 53. This upward forcegenerates a reaction downward force F2, F2′ in the walls of outer tube14A of column 14, which downward forces becomes applied to thefoundation or floor 22. Also, as previously described, the upward forceF1 applies force vectors F3 and F4 to pin 43 for drawing the wall panelsinward and upward.

A number of different foundations or floors may be employed depending onthe land conditions, equipment and materials available or still otherfactors. For example, there may be a poured concrete floor covering theentire area of the building to be erected, or there may be onlyindividual pilings or jack stand foundations situated at the site ofeach upright support column, or some combination of the above. In allcases it is necessary to establish a very strong fixed anchor element ateach location below an upright support column.

FIGS. 7, 7A, 9, 10 and 12 illustrate a horizontal anchor pin 53 embeddedin jack stand 100 (FIGS. 7, 7A, and 9) or embedded in floor 22 (FIGS. 10and 12). Engaged to anchor pin 53 in each figure is hook 52 at thebottom end of rod 51. Because of the relationship of the generally roundcross-section of hook 52 and round cross-section of the hook, rod 51 caneasily angulate in all directions from straight to accommodate anyfailure of a column 14 to be situated directly over the center of pin 53and rod 51.

The later connection of the top end of rod 51 to the bottom end of drawbar 25 has been described above. FIG. 12 shows how the slot 58 in blade56 and pin 59 in slot 58 arrangement allows further angulation of rod51, if necessary. FIG. 18 illustrates a rod 55 fixed in a foundation,but including blade 56, slot 58 and pin 59. A typical jack stand, asseen in FIG. 7A, has a truncated pyramid shape with a seven inch squareplate at the top, and eighteen inch square plate at the bottom, and atwenty-four inch height.

G. Roof Assembly and Connection to Side Walls

FIGS. 1, 7B, 13, 14, 14A and 14B illustrate the haunch coupling of theroof truss to support columns 14. In this roof truss system horizontalroof beams 80 span the space between side walls 11, with each endportion 80A of a beam 80 removably coupled to the top portion of oneupright support column 14. As seen in FIGS. 14 and 14A, end portion 80Aof beam 80 rests upon block 68 which rests on cut-out ledges 14X, 14Y ofthe front and rear walls 14C, 14D respectively of outer tube 14A ofcolumn 14. Rod 66 extends upward from block 65 in draw bar's clearancehole 68A in block 68. Lock down nut 74, when rotated, pulls draw bar 25upward to its maximum height set by slot 58 situated at the bottom ofouter tube 14A (see FIG. 12). In this upward position, with nut 74tightened down, adjacent wall panels 12 will be drawn in to theirconnect position of elevation and closeness to column 14. This fixes andstabilizes the wall panels to the column and locks down that column andpanels to the floor or anchor.

Horizontal beams 80 join and support the opposite side walls 11. Eachinclined roof beam 81 is situated between the facing side edges of twoadjacent roof panels 18, which are drawn securely toward beam 81 by aninternal draw bar similar to draw bars 25 employed in the side wallconstruction. Roof panels 18 are sufficiently light weight that they canbe easily lifted, positioned and secured to roof beams 81. As evident inFIG. 13, the single lock down nut 74 secures the wall panels into a wallconstruction, and the single lock down nut 82 secures roof beams 80, 81to the wall structure.

Roof beams 81 are partially similar to support columns 14, in that eachincludes a slidable draw bar and sets of fixed and movable wings forengaging pins in pockets of roof panels 12, which are generally similarto wall panels 12. A series of alternatively spaced roof panels 18 androof beams 20 create a roof section 70. As seen in FIG. 16, which is asectional view taken from FIG. 1, each two adjacent roof panels 18joined by a roof beam 20 have additional sealing strip elements 71, 72which extends from one panel toward the other and include internalgasket 74. When two adjacent roof panels 18 are drawn and secured to aroof beam 20, as seen in FIG. 16, seal strip 71 automatically slidesover and resiliently locks by the hook part 73 onto seal strip 72. FIG.17 shows an additional seal 75 for adjacent top edges of two roofsections.

The alternative roof truss system of FIG. 1 includes lower horizontalroof beams 90, inclined roof beams 91, longitudinal roof truss headerbeam 92, and side wall header beams 93 which interconnect the top partsof support columns 14 of the side walls. With this roof truss systemthat is independent of the roof panels, the roof section is assembled ofpanels 18 and support beams 20, one-after-another, into a roof sectionthat lies upon and is supported by the basic roof truss system.

This arrangement demonstrates another aspect of the present inventionwhich reduces labor, parts, and cost and thus speeds erection of thebuilding, while assuring a reliable seal.

H. Corner Wall Structure

As seen in FIGS. 1 and 15, the corner construction of side walls 11 andend walls employs a corner upright support column 101 and draw bar 102generally similar to a column 14 and draw bar 25, except that the wings29, 30 in this corner embodiment extend at a right angle to each other,so that they can engage and couple to the side and end wall panels 11respectively. Pulling up on draw bar 102 will cause wings 29, 30 toconnect with pins 43 of the respective panels and to draw these panelsinward against column 101.

I. Floor

The floor 22 as seen in FIG. 1 is poured concrete or other material withanchor or hold-down rods 51 or 55, as seen in FIGS. 12 and 18respectively, embedded or secured in the floor. The floor may be asprimitive as bare dirt, so long as the anchor elements 23 are strongenough and sufficiently embedded to securely hold down and stabilize thewalls attached to said anchor elements.

The floor may alternatively be constructed of floor panels in a mannergenerally similar to construction of a wall 11, with floor beams anddraw bars between facing side edges of adjacent floor panels.

Strength, heat and sound insulation properties would be designed intofloor, wall and roof panels as desired. These panels may also includemodular segments of HVAC, electrical telecommunication wiring, plumbing,etc. so that assembly of the panels into floor, wall and roof sectionsautomatically creates the basic network of HVAC, electrical,telecommunicating and plumbing systems.

J. Steps in Erection of Building

For this description of the building erection procedure, it shall beassumed that a variety of preliminary steps have been completed, namely:

(a) that the components are constructed and are readily available at theerection site, these components including all the wall panels 12, roofpanels 18, support column and draw bar units 14/25, and roof beams andcorresponding draw bar units 20, and

(b) that all the anchor pins 53 and upward extending anchor rods 51 arepositioned and secured either in a poured concrete floor or in pilings,jack stands or in other foundation means, all at the reasonably accurateelevation and distances from each other.

The next steps in the preferred method of erection of the building areas follows; however, numerous variations are possible:

1. Position a corner wall support column 101 as seen in FIGS. 15 and 1)this support column has two panel-engaging sides 90° apart, above theanchor pin in the corner location;

2. Bring the side edge of a side wall panel into close proximity witheach of said panel-engaging sides of said corner column, until each setof first coupling elements (2A-3E), namely each set of upper and lowerwings 29, 30 on each panel-engaging side of the corner column enters acorresponding recess 42 of one of the second coupling elements 3A-3E ina side edge of the panel, until the coupling pin 43 in each recess iscorrectly in the space 46 between said wings. If necessary the taperededges of wings 29 will guide or cam pin 43 to the correct elevation,thus correctly positioning the panel as regards its orientation andelevation, see FIG. 8. Both panels 12 oriented 90° apart are now ininitial engagement with corner support column 101. It is assumed at thistime that the lower end 14B of draw bar 102 is properly connected to theanchor pin directly below support column 101.

3. Pull upward draw bar 102 (FIG. 15) until each pins 43 is securelypositioned between each set of wings 29, 30, and the panels are drawninto proper position and secure engagement with column 101, the columnbeing securely connected to anchor pin 43 below the column.

4. Two wall panels 11 (FIG. 15,1) at 90° to each other are nowupstanding and coupled to the corner column 101, and each of these wallpanels has an exposed opposite side edge remote from the side edgecoupled to the corner column. Adjacent each of said exposed side edgesof the panels is positioned a new support column 14. The draw bar 25 ofeach new support column is coupled to an anchor pin below it, which mayrequire tilting of the column and may require momentarily sliding thebottom end of draw bar 25 out of the bottom end of the outer tube 14A.For convenience, the above-mentioned first wall panel forming the cornerwill be designated Panel 1. The new support column adjacent to theexposed edge of Panel 1 will be designated Column 1.

5. In addition to connecting Column 1 to its anchor pin, Column 1 isadjusted in position and orientation so that its coupling elements(2A-3E), namely wings 29, 30 are maneuvered into coupling elements(3A-3E), namely pockets or recesses 2 in the exposed side of Panel 1;however, coupling of Column 1 and Panel 1 is not yet complete.

6. A new wall Panel 2 is now positioned adjacent the other side ofColumn 1, until the coupling elements (2A-2E) namely, the sets of wingsof Column 1, enter corresponding coupling elements (3A-3E) namelyrecesses 42 in the adjacent side edge of Panel 2.

7. Next, draw bar 25 within Column 1 is pulled upward which draws Column1 toward Panel 1 and draws Panel 2 toward Column 1, until Panel 2 isupright and properly aligned, consistent with Panel 1.

8. As seen in FIGS. 19, 20, and 21, this procedure is repeated for thelength of the side wall, followed by attachment of another cornercolumn, followed by attachment of “end” wall panels.

9. With the walls 10 essentially complete, horizontal roof beams 80 arepositioned with their ends 80A coupled into the top ends of oppositecolumns 14 in opposite side wall 10. The upstanding rod 66 of eachcolumn 14 extends through holes in said ends of roof beams 80.

10. Next, an inclined roof beam 81, which includes a draw bar assemblyfor engaging roof panels, is positioned with its lower end positionedadjacent the end 80A of beam 80 top wall column. Rod 66 extends throughboth beams, and lock-down nut 82 is installed to secure both beams tocolumn 14. The upper ends of roof beams are supported by a header beam92 extending lengthwise of the building, FIG. 1.

11. Next, a first roof panel 18 is positioned with one side edge and itsrecesses closely adjacent a first roof beams, until the sets of wingsenter the pockets in the side edge of the first roof panel. The draw barin beam 81 is pulled axially until roof panels on both sides aredrawn-in and properly and snugly positioned.

12. Additional roof beam/draw bar component and roof panels areconsecutively placed in a manner generally similar to the erection of aside wall and is continued to complete one side of a gabled roof.

13. A variety of subsequent finishing steps will be executed asselected, including connection of electrical, water and HVAC componentsthrough panels and columns. Various details associated with individualcomponents and discussed above, such as connecting the bottom of eachdraw bar to the corresponding anchor pin, have not been described again.Also, not described here are methods of accurately positioning andestablishing the correct elevation of jack stands and anchor pins.

K. Construction of a Wall Panel

Wall panels as seen in FIGS. 2-6, having the dimensions and physicalproperties required for a prefabricated building as described herein,may be made by numerous manufacturing processes; however, the preferredprocess which is consistent with concepts of the present invention:

(a) uses non-wood materials such as plastics, fiberglass and compositeswhich reduce consumption of forests, and which have good heat and coldinsulation properties and thus further reduce the consumption of woodand other natural resources and energy for heating and cooling,

(b) uses methods and manufacturing equipment that can be easilytransported, set up and used to produce wall panels and support columnsat very high speed and low cost,

(c) produces panels that are strong yet extremely light weight so thattransport, storage, and assembly will not require heavy equipment, and

(d) produces panels which can have a great variety of textured, colored,aesthetic and functional external and internal surfaces.

The new panels seen in FIGS. 2 and 4 are manufactured by a method usinga mold shown schematically in FIG. 22 which includes the followingsteps:

Step 1: The skins 44A, 44B of each panel are fabrics which comprise twolayers of fiberglass and/or Kevlar carbon fiber (matte andunidirectional) with polyester resin which (a) may be wetted out byhand, or (b) may be wet from prepregnated resin, or (c) may have resininjected into a closed mold which already contains the fabric sheets.These panels have a Class 1 fire rating.

Step 2: The internal frame 40 of each panel comprises two identical sidelegs 44, each having equally spaced pockets 42 and top and bottom endlegs 39 whose ends are joined to the side legs to form a picture frame;however, the top leg includes a rake angle from front to rear toaccommodate the slope of the roof. Thus, the inside of the picture frameand the inside skin 44A will be slightly taller than the outside skin44B, as seen in FIG. 4A. Instead of joining side and end legs, the legsof this picture frame can be formed in a single step mold. This framemay be made of a fiber glass and resin combination or of any othermaterials having suitable strength characteristics for the temperatureand environmental conditions of molding and of use in buildings.

Step 3: A mold, as seen in FIG. 22, holds the fabric sheets and frame ofa single panel. Urethane foam 38 is injected into the space within theframe and between the skins, the skins are bonded to the frame, and aunitary one-piece panel is created. Thereafter, holes are drilled ormachined to receive pins 43 for coupling to the previously describedsupport column/draw bar subassemblies 14. Optimally, pins 43 may beplaced within the mold before injection.

Step 4: The top and bottom legs 39 of each frame include holes 86 alongtheir length to receive injection nozzles (not shown) for entry of theurethane foam that expands 1200% in 40 seconds. Hole size depends on thevolume of the cavity and the speed of the urethane. After injection, thenozzles are retracted and the holes are sealed. Heat from and duringinjection is about 100° F. which is maintained for about 45 seconds.

Step 5: For each panel, injection cycle time is one minute and cure timeis 10 minutes. The fiberglass skin may be manually placed in the mold,or with a PFE (Precision Feed End Effector) the skin can be laid up inthe mold with optional wet, dry or prepreg gel coat, or the gel coat maybe sprayed inside the mold before the skin is situated therein.Preferably a robot will apply the gel coat since it is highlycombustible and the robot is sufficiently explosion-proof. Also, therobot can maneuver into confined compartments or unfriendly environmentsand can move molds with gel coat to safer location.

Step 6: The fiber glass and epoxy mold 83 in a preferred embodimentopens like front and rear book covers 83A open from the core pages of abook.

End plates 84 of the mold overlie the top and bottom beams 39 of thepicture frame 40. Holes 85 in end plates 84 are aligned with holes 86 insaid top and bottom beams 39 of frame 40, so that injected foam can passthrough the mold end plates and the frame end wall, into the panelcavity 87. The skins 44A, 44B will become bonded to frame 40.

Step 7: High Speed Manufacturing Sequences:

With selected number and sequencing of molds, panels can be made at therate of one per minute or theoretically 43, 200 per month with thisarrangement:

(a) skins are made at the rate of one per minute,

(b) frames are made at the rate of one per minute,

(c) two skins and one frame converge to form a panel cartridge (withinjection and 1200% expansion in 4 seconds) and movement of mold to acooling line for ten minutes, and

(d) with ten cooling lines, each taking ten minutes, a staggeredarrangement will produce one panel every minute. This is illustrated inattached Appendix A.

This is all robot controlled and thus requires essentially no humanlabor except for basic supervision and maintenance. This panelconstruction is applicable for wall, roof and/or floor panels. Panelshape may be flat, curved or otherwise. Surface texture, color, graphicsor other esthetic on interior and exterior panel surface is possible.

V. SUMMARY

This invention discloses a variety of embodiments of the newprefabricated building structure, components and methods of manufacture,including:

(a) a whole building comprising walls, roof and floor or foundation,

(b) the subassembly of a single wall or portion of one wall,

(c) the sub-assembly of a single support column and one or two attachedpanels,

(d) a single support column and slidable internal shaft,

(e) roof and floor sub-assemblies,

(f) a method of erecting a building constructed of the new panels andsupport columns,

(g) a method of manufacturing a single wall panel, and

(h) a kit components for assembling or erecting a building, or a wall,or a wall section.

Summaries of certain ones of the above-described embodiments of thisinvention are presented below.

A first embodiment of the present invention is a prefabricated wallcomprising:

(a) a plurality of wall panels and a plurality of columns for supportingsaid wall panels, where each of said columns and panels has top andbottom parts, inner and outer surfaces and opposite side edges, and saidpanels and columns are adapted to be alternately spaced and joinedtogether, with each of said columns situated between two of said panelsto form a wall section,

(b) coupling means for each of said wall sections for releasablyattaching one side edge of each of said two panels to each side edge ofsaid column, and

(c) activating means on said column of each of said wall sections foractivating each of said coupling means,

-   -   wherein each of said coupling means comprises:    -   (1) at least one 1^(st) coupling element situated on one side        edge of said column, and    -   (2) at least one 2^(nd) coupling element on the side edge of the        panel being coupled, said column and panels being laterally        movable relative to each other until said 1^(st) and 2^(nd)        coupling elements of said column and of said wall panels        respectively come into engagement, and

said activating means being adapted to drive said 1^(st) couplingelement generally vertically which drives said 2^(nd) coupling elementsgenerally horizontally, thus driving said side edges of said panels andcolumn toward each other.

A second embodiment of the present invention is a prefabricated wall asdescribed in said first embodiment, wherein

(a) said first coupling element of each of said wall sections comprises:a 1st wing:

-   -   (1) fixed to each of said side edges of said shaft,    -   (2) extending laterally outward therefrom and terminating in and        end part which includes a cam surface inclined inwardly toward        said shaft, and    -   (3) movable upward when said shaft is driven upward, and

(b) said side edge of said wall panel defines a recess extending inwardinto said panel and thus extending away from said shaft, and

(c) said second coupling element comprises a pin fixed in said recess insaid wall panel and extending in the inside-to-outside direction, saidcam surface of said first coupling element, when said shaft is drivenupwardly by said activating means, camming said pin and associated wallpanel toward to said column.

A third embodiment is a prefabricated wall according to said secondembodiment, adapted to be erected on and attached to a foundation whichincludes anchor means secured in said foundation, wherein:

-   -   (a) said column outer tube comprises walls extending from said        top part of said column downward to and engaging said        foundation,    -   (b) said inner shaft extends axially in said outer tube, and    -   (c) said activating means driving said inner shaft upward        relative to said tube, which puts said shaft in tension relative        to said tube and puts said tube walls in compression relative to        said foundation, where said lifting said shaft lifts said 1^(st)        wing and its cam surface therein cams said pin and panel        attached to said pin inwardly toward said shaft.

A fourth embodiment is a prefabricated wall according to said firstembodiment, wherein each of said wall panels comprises:

(a) a generally rectangular frame formed by top, bottom and side edgebeams which define between then a central space,

(b) a core of heat insulation material substantially filling saidcentral space and secured therein, and

(c) inner and outer skins covering said inner and outer sidesrespectively of said frame and core.

A fifth embodiment is a prefabricated wall according to said firstembodiment adapted to be erected on and attached to a foundation whichis secured in the ground and includes anchor means fixed in saidfoundation and spaced apart to locations corresponding to each of saidcolumns, where each of said columns comprises an outer tube with a boreextending lengthwise, and an inner shaft axially slidable upward in saidouter tube bore, said inner shaft having a bottom end adapted toreleasably engage one of said anchor means, and said inner shaft whenpulled upwardly relative to said column, pulls upwardly on said anchormeans causing a downward force of said outer tube on said foundation andtension on said inner shaft, as said wall panels are drawing toward saidcolumn.

A sixth embodiment is a kit for constructing a prefabricated wall, saidkit comprising:

(a) a plurality of wall panels and a plurality of columns for supportingsaid wall panels, where each of said columns and panels has top andbottom parts, inner and outer surfaces and opposite side edges, and saidpanels and columns are adapted to be alternately spaced and joinedtogether, with each of said columns situated between two of said panelsto form a wall section,

(b) coupling means for each of said wall sections for releasablyattaching one side edge of each of said two panels to each side edge ofsaid column, and

(c) activating means on said column of each of said wall sections foractivating each of said coupling means,

wherein each of said coupling means comprises:

-   -   (1) at least one 1^(st) coupling element situated on one side        edge of said column, and    -   (2) at least one 2^(nd) coupling element on the side edge of the        panel being coupled, said column and panels being laterally        movable relative to each other until said 1^(st) and 2^(nd)        coupling elements of said column and of said wall panels        respectively come into engagement, and        -   said activating means being adapted to drive said 1^(st)            coupling element generally vertically which drives said            2^(nd) coupling elements generally horizontally, thus            driving said side edges of said panels and column toward            each other.

A seventh embodiment is a generally rectangular prefabricated buildingerected on a floor area and attached to anchor means in said floor area,comprising:

(a) four walls as defined in said second embodiment, where each wallextends upright and laterally to predetermined lengths respectively andterminates in opposite ends,

(b) corner coupling for joining adjacent ends of two walls,

(c) a roof secured to said top parts of at least two of said walls, and

(d) each of said columns of each of said walls having an internal shaftwith a bottom end engagable to said anchor element and a top partadapted to be pulled upward relative to said column top at, therebycausing said shaft to be in tension, said column bottom part to pressdownward against said floor area, and said coupling means thereon to beurged upward.

An eight embodiment is a method of manufacturing a wall panel with aninjection mold having front and rear and edge covers, where at least oneedge cover includes an injection inlet means, and at least one edgecover includes outlet vent means, comprising the steps:

(a) positioning a generally rectangular frame having inner and outersides in said mold, said frame defining within it a central cavity,

(b) positioning inner and outer skins adjacent the inner and outer sidesof said frame to enclose said central cavity,

(c) covering said skins with said front and rear covers of said mold,

(d) securing said front and rear covers and said end plates onto saidmold,

(e) injecting expandable urethane plastic into said cavity,

(f) venting said cavity via apertures in said frame and mold,

(g) bonding said skins to said frame,

(h) cooling said mold and molded panel therein,

(i) opening said covers and end plates, and

(j) removing said panel from said mold.

A ninth embodiment is a method of erecting a prefabricated buildingaccording to said seventh embodiment, comprising the steps:

(a) establishing a (generally horizontal) floor area on which to erectsaid building,

(b) securing anchor means in said floor area at predetermined locationsand a generally common elevation,

(c) positioning and erecting a corner column at a corner location forsaid building above a corresponding anchor means and engaging said shaftof said corner column to said anchor means,

(d) positioning said first wall panel with one of its end edges adjacentone side edge of said corner column, moving said will panel laterallyuntil said coupling elements of said corner column enter said recessesof said first wall panel, and elevating said shaft to engage and draw-insaid wall panel to said column,

(e) positioning and erecting a first column adjacent said opposite sideedge of said first wall panel and positioned above said anchor meanscorresponding to said first column, engaging said shaft of said firstcolumn to said anchor means, and positioning said first couplingelements of said first column in recesses in said opposite side edge ofsaid first wall panel, and

(f) elevating said shaft of said first column for its first couplingelements to engage and draw together said opposite side edge and saidfirst column, to simultaneously secure said first column to its anchormeans.

While the invention has been described in conjunction with severalembodiments, it is to be understood that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, this inventionis intended to embrace all such alternatives, modifications, andvariations which fall within the spirit and scope of the appendedclaims.

1. A prefabricated wall comprising: a. a plurality of wall panels and aplurality of columns for supporting said wall panels, where each of saidcolumns and panels has top and bottom parts, inner and outer surfacesand opposite side edges, and said panels and columns are adapted to bealternately spaced and joined together with each of said columnssituated between two of said panels to form a wall section, b. couplingmeans for each of said wall sections for releasably attaching one sideedge of each of said two panels to each side edge of said column, and c.activating means on said column of each of said wall sections foractivating each of said coupling means, wherein each of said couplingmeans comprises: (1) at least one 1^(st) coupling element situated onone side edge of said column, and (3) at least one 2^(nd) couplingelement on the side edge of the panel being coupled thereto, said columnand panels being laterally movable relative to each other until said1^(st) and 2^(nd) coupling elements of said column and of said wallpanels respectively come into engagement, said activating means beingadapted to drive said 1^(st) coupling element generally vertically whichdrives said 2^(nd) coupling elements generally horizontally, thusdriving said side edges of said panels and column toward each other. 2.A prefabricated wall according to claim 1 wherein said column of each ofsaid wall sections comprises: a. an outer tube having top and bottomparts and a bore extending lengthwise, and b. an inner shaft having topand bottom parts and opposite side edges and being axially slidableupwardly in said outer tube bore, C. said activating means being adaptedto drive said inner shaft axially between an initial open position to aclosed position where said wall panels are drawn toward said column. 3.A prefabricated wall according to claim 2, wherein (a) said activatingmeans of each of said wall sections comprises an external lead screw onsaid top part of said inner shaft and a mating threaded nut at said toppart of said outer tube whereby rotation of said nut draws said shaftupward.
 4. A prefabricated wall according to claim 2, wherein a. saidfirst coupling element of each of said wall sections comprises: a 1stwing that is: (1) fixed to each of said side edges of said inner shaftand extending laterally outward therefrom and terminating in and endpart which includes a cam surface inclined inwardly toward said innershaft, and (2) movable upward when said inner shaft is driven upward,and b. said side edge of said wall panel defines a recess extendinginward into said panel and thus extending away from said shaft, and c.said second coupling element comprises a pin fixed in said recess insaid wall panel and extending in the inside-to-outside direction, saidcam surface of said first coupling element, when said inner shaft isdriven upwardly by said activating means, camming said pin andassociated wall panel toward to said inner shaft.
 5. A prefabricatedwall according to claim 4, further comprising a second wing situated onsaid side edge of said outer tube axially above said first wing on saidinner shaft, said first wing when driven upward by upward movement ofsaid inner shaft, capturing said pin between it and said second wingfixed to said outer tube.
 6. A prefabricated wall according to claim 4,adapted to be erected on and attached to a foundation which includesanchor means secured in said foundation, wherein: (d) said column outertube comprises walls extending from said top part of said columndownward to and engaging said foundation, and (e) said activating meansdriving said inner shaft upward relative to said outer tube, puts saidinner shaft in tension relative to said outer tube and puts said outertube walls in compression relative to said foundation, said upwardmovement of said inner shaft relative to said outer tube also lifts said1^(st) wing and its cam surface therein which cams said pin and panelattached to said pin inwardly toward said inner shaft.
 7. Aprefabricated wall according to claim 2 adapted to be erected on andattached to a foundation which includes anchor means secured in saidfoundation, wherein, a. said inner shaft further comprises 1^(st) firstmeans for engaging said anchor means, b. said outer tube comprises2^(nd) means fixed to said outer tube for engaging and driving saidinner shaft upward relative to said outer tube, which puts said innershaft in tension and creates an opposite downward force on said outertube when it is urged against said when outer tube against saidfoundation, and c. where said upward movement of said inner shaft and1^(st) coupling element thereon creates a cam force for urging said2^(nd) coupling element laterally inward toward said outer tube whensaid inner shaft is moved upward.
 8. A prefabricated wall according toclaim 1, wherein said wall panel end edge defines therein a recess withsaid pin mounted in said recess, and said 1^(st) coupling element isextendable into said recess to engage said pin.
 9. A prefabricated wallaccording to claim 1, wherein said 1^(st) coupling element includes aninclined cam surface for driving said pin laterally toward said columnwhen said shaft is driven upwardly.
 10. A prefabricated wall accordingto claim 2, wherein said outer tube is formed by walls, two of whichform said opposite side edges of said column, each of these two wallsdefining therein an elongated slot through which said 2^(nd) couplingelement carried by said inner shaft can extend, and said wing is fixedto said side wall of said outer tube above said slot.
 11. Aprefabricated wall according to claim 1, wherein said wall panel isformed as a laminate having length in said top-to-bottom direction,width in said side-to-side direction, thickness in said inner-to-outerdirection and has exposed side edges, each of said side edges having aplurality of pocket-like recesses extending inwardly and spaced apartalong said length, and said wall panel further comprises in each of saidrecesses a pin situated inward of said side edge and extending in saidinner-to-outer direction, said pin configured to be engagable by said1^(st) coupling element extending from said inner shaft.
 12. Aprefabricated wall according to claim 11, wherein each of said wallpanels comprises: a. a generally rectangular frame formed by top, bottomand side edge beams which define between then a central space, b. a coreof heat insulation material substantially filling said central space andsecured therein, and c. inner and outer skins covering said inner andouter sides respectively of said frame and core.
 13. A prefabricatedwall according to claim 12 wherein for each of said wall panels: a. saidframe is injection molded of plastic, b. said core comprises heatinsulating expandable urethane, and c. said skins comprise fiber glass,Kevlar® carbon fiber or other composite.
 14. A prefabricated wallaccording to claim 4, wherein said top wing has a bottom surface that isgenerally horizontal extending outward from said outer tube and thentapers upward at its end part to easily receive said pin in said wallpanel recess.
 15. A prefabricated wall according to claim 4, wherein oneach side edge of said outer tube and adjacent side edge of said innershaft said top wing and bottom wing are displaced relative to each otherin the inner-to-outer direction.
 16. A prefabricated wall according toclaim 4, wherein said top wing on one side edge of said outer tube isdisplaced forward of said top wing on the opposite side edge of saidouter tube, and said bottom wing is displaced rearward of said bottomwing on the opposite side edges of said inner shaft.
 17. A prefabricatedwall according to claim 1 adapted to be erected on and attached to afoundation which is secured in the ground and includes anchor meansfixed in said foundation and spaced apart to locations corresponding toeach of said columns, where each of said columns comprises an outer tubewith a bore extending lengthwise, and an inner shaft axially slidableupward in said outer tube bore, said inner shaft having a bottom endadapted to releasably engage one of said anchor means, and said innershaft when pulled upwardly relative to said column, pulls upwardly onsaid anchor means causing tension on said inner shaft and a downwardforce of said outer tube on said foundation as said wall panels aredrawn toward said column.
 18. A wall according to claim 17, wherein saidactivating means further comprises adjustment means (a) to allow upwardmovement of said inner shaft while said inner shaft draws inward saidwall panels toward said column, and thereafter (b) to couple said innershaft to said anchor means which resists further upward movement of saidinner shaft, which thereafter goes into tension as said outer tube wallsgo into compression.
 19. A wall according to claim 18, wherein saidadjustment means comprises a blade with an elongated axial slot thereinconnected to said anchor, and a pin mounted to said inner shaft andextending transversely through said slot, where axial movement of saidinner shaft moves said pin to the top end of said slot.
 20. A kit forconstructing a prefabricated wall, said kit comprising: a. a pluralityof wall panels and a plurality of columns for supporting said wallpanels, where each of said columns and panels has top and bottom parts,inner and outer surfaces and opposite side edges, and said panels andcolumns are adapted to be alternately spaced and joined together, witheach of said columns situated between two of said panels to form a wallsection, b. coupling means for each of said wall sections for releasablyattaching one side edge of each of said two panels to each side edge ofsaid column, and c. activating means on said column of each of said wallsections for activating each of said coupling means, wherein each ofsaid coupling means comprises: (1) at least one 1^(st) coupling elementsituated on one side edge of said column, and (2) at least one 2^(nd)coupling element on the side edge of the panel being coupled, saidcolumn and panels being laterally movable relative to each other untilsaid 1^(st) and 2^(nd) coupling elements of said column and of said wallpanels respectively come into engagement, and said activating meansbeing adapted to drive said 1^(st) coupling element generally verticallywhich drives said 2^(nd) coupling elements generally horizontally, thusdriving said side edges of said panels and column toward each other. 21.A kit for a prefabricated building adapted to be erected above a floorarea which includes anchor elements spaced apart and secured in saidfloor area, said kit comprising a plurality of wall panels and columnsfor constructing walls as defined in claim 18, each of said walls havingopposite ends which are releasably joinable to define an enclosure, andsaid inner shafts of said columns of said walls being releasablyconnectible to said anchor elements.
 22. A kit according to claim 20,wherein said 2^(nd) coupling element comprises a pin mounted in saidwall panel, said pin being engagable by said 1^(st) coupling element.23. A generally rectangular prefabricated building erected on a floorarea and attached to anchor means in said floor area, comprising: a.four walls as defined in claim 2, where each of said walls extendsupright and laterally to predetermined lengths respectively andterminates in opposite ends, b. corner columns for joining adjacent endsof two walls, and c. a roof secured to said top parts of at least two ofsaid walls, and d. for each of said walls each of said inner shafts hasa bottom end engagable to one said anchor elements and a top partadapted to be pulled upward relative to said outer tube top part,thereby causing said inner shaft to be in tension and said outer tubebottom part to press downward against said floor area, and said 1stcoupling elements to be urged upward, thus driving said wall panelstoward said column.
 24. A prefabricated building according to 23wherein, each of said columns comprises: (1) an outer tube, (2) an innershaft axially movable within said outer tube, (3) 1^(st) means at thebottom part of said inner shaft adapted to engage one of said anchors,(4) 2^(nd) means carried by said inner shaft and adapted to engage saidadjacent panels, and when driven upward to pull said engaged panelslaterally inward toward said inner shaft, and (5) 3^(rd) means adaptedto draw said 2^(nd) means upward while bearing downward against saidouter tube, thereby putting said inner shaft in tension and urging saidouter tube downward against said foundation when said inner shaft ispulled upward and said adjacent wall panels are pulled laterally towardsaid outer tube.
 25. A building according to claim 23 further comprisinga roof truss formed of a plurality of roof beams extending across saidbuilding between the tops of two opposite walls, each of said roof beamsreleasably coupled to one of said columns at the top part in a haunchconnection comprising: a. a threaded rod extending upward from saidinner shaft and freely through said nut plate, b. an aperturedtransverse plate fixed to said outer tube, c. a nut drawing saidthreaded rod and inner shaft upward, and d. said rod extending furtherupward and through an aperture in said end of said roof beam, and afurther nut to secure same.
 26. A building according to claim 23,wherein each of said corner columns comprises an outer tube and innershaft wherein said side edges of said outer tube are 90 degrees apart,and side edges of said inner shaft correspond to said side of said outertube.
 27. A method of manufacturing a wall panel having inner and outersides with an injection mold having inner and outer covers and edgecovers, at least one edge cover including an injection inlet means andat least one edge cover including outlet vent means, comprising thesteps: a. positioning a generally rectangular frame having inner andouter sides corresponding to said inner and outer sides of said wallpanel in said mold, said frame defining within it a central cavity, b.positioning inner and outer skins adjacent the inner and outer sides ofsaid frame to enclose said central cavity, c. covering said skins withsaid front and rear covers of said mold, d. securing said inner andouter covers and said edge covers onto said mold, e. injectingexpandable urethane plastic into said cavity, f. venting said cavity viaapertures in said frame and mold, g. bonding said skins to said frame,h. cooling said mold and molded panel therein, i. opening said covers,and j. removing said panel from said mold.
 28. A method of manufacturinga wall panel comprising the steps: a. providing a book-like mold havingmovable front and rear covers for defining between them a mold spacethat corresponds generally to the length, width and thickness of a panelto be made, b. positioning a generally rectangular frame in said moldspace, said frame defining within it a central cavity, c. positioningfront and rear skins adjacent the front and rear sides of said frame toenclose said central cavity, d. covering said skins with said front andrear covers of said mold, e. covering ends of said frame and closingsaid mold with end plates, f. securing said front and rear covers andsaid end plates onto said mold, g. injecting expandable urethane plasticinto said cavity, h. venting said cavity via apertures in said frame andmold, i. bonding said skins to said frame, j cooling said mold andmolded panel therein, k. opening said covers and end plates, and l.removing said panel from said mold.
 29. A method of manufacturing a wallpanel according to claim 27, comprising the steps: a. positioning1^(st), 2^(nd) and 3^(rd) production lines for simultaneously producing1^(st) and 2^(nd) skins and one frame every minute, b. directing fromsaid 1^(st), 2^(nd) and 3^(rd) production lines, every minute, two skinsand one frame to a final mold station where each panel is made in a fewseconds, and c. directing the output of panels from said final moldstation sequentially at the rate of one per minute to 1^(st)-10^(th)cooling stations, so that after ten minutes the panel at the 1^(st)cooling station is completed and this station is ready to receive a newpanel to begin its 10 minute cooling phase, thus producing from 10cooling stations together, one cooled panel every minute.
 30. A methodof manufacturing a wall panel according to claim 27, comprising thesteps: a. a. positioning 1^(st), 2^(nd) and 3^(rd) production lines forsimultaneously producing “x” quantity of 1^(st) and 2^(nd) skins and oneframe every minute, b. directing from said 1st, 2^(nd) and 3^(rd)production lines every minute, “x” number of 1st and 2^(nd) skins andone frame to a final mold station where each panel is made in a fewseconds, and c. directing the output of “x” quantity of panels perminute from said final mold station sequentially at the rate of “x” perminute to “y” quantity of cooling stations, so that after “y” minutesthe panel at the 1^(st) cooling station is completed and this station isready to receive a new panel to begin its “y” minute cooling phase, thusproducing from said final mold station “x” panels per minute andproducing in the aggregate from said Y cooling stations “x” cooledpanels per minute.
 31. A method of erecting a prefabricated buildingusing prefabricated walls, columns and corner columns as defined inclaim 26, comprising the steps: a. establishing a floor area on which toerect said building, b. securing anchor means in said floor area atpredetermined locations, c. positioning and erecting a corner column ata corner location for said building above a corresponding anchor meansand engaging said inner shaft of said corner column to said anchormeans, d. positioning said first wall panel with one of its end edgesadjacent one side edge of said corner column, moving said wall panellaterally until said is 1^(st) and 2^(nd) coupling elements of saidcorner column enter said recesses of said first wall panel, andelevating said inner shaft to engage and draw-in said wall panel to saidcolumn, e. positioning and erecting a first of said columns (“firstcolumn”) adjacent said opposite side edge of said first wall panel andpositioned above said anchor means corresponding to said first column,engaging said inner shaft of said first column to said anchor means, andpositioning said first coupling elements of said first column inrecesses in said opposite side edge of said first wall panel, f.elevating said inner shaft of said first column for its first couplingelements to engage and draw together said opposite side edge and saidfirst column, and to simultaneously secure said first column to itsanchor means, and g. successively similarly attaching columns and wallpanels to complete said walls of predetermined length and includedcorner columns to define a building enclosure.